Floor panel

ABSTRACT

Floor panel, with a horizontally and vertically active locking system allowing that two of such floor panels can be connected to each other at said sides by providing one of these floor panels, by means of a downward movement, in the other floor panel; wherein the vertically active locking system comprises a locking element in the form of an insert; wherein this locking element comprises at least a pivotable lock-up body; characterized in that the pivotable lock-up body comprises a support portion which is rotatable against a support surface pertaining to the floor panel concerned, and more particularly in a seat.

This invention is a continuation of application Ser. No. 14/626,444,filed Feb. 19, 2015, which is a continuation of Ser. No. 14/104,685,filed Dec. 12, 2013, now U.S. Pat. No. 8,966,852, which is acontinuation of application Ser. No. 12/744,231, filed May 21, 2010, nowU.S. Pat. No. 8,621,814, which claims the benefit of U.S. provisionalapplication No. 61/071,201, filed Apr. 17, 2008.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a floor panel.

More particularly, it relates to a floor panel comprising coupling partsat least at two opposite sides, in the form of a male coupling part anda female coupling part, respectively, which allow to connect two of suchfloor panels to each other at the aforementioned sides by providing oneof these floor panels with the pertaining male coupling part, by meansof a downward movement, in the female coupling part of the other floorpanel, such that thereby at least a locking in horizontal direction isobtained.

2. Related Art

Couplings allowing to couple two floor panels to each other by joiningone floor panel with a downward movement into the other, in practice aresubdivided into two kinds, namely a first kind wherein the couplingparts exclusively provide for a horizontal locking, without any presenceof a locking in vertical direction, and a second kind wherein ahorizontal as well as a vertical locking are provided for.

The couplings of the first kind are also known as so-called “drop-in”systems. Floor panels equipped with those at two opposite sides areknown, amongst others, from CA 991.373 and JP 07-300979. As is evidentfrom these patent documents, such “drop-in” systems often are onlyapplied at a first pair of opposite sides of the floor panels, whereasthen at the second pair of opposite sides, coupling parts are appliedwhich, in the coupled condition of two floor panels, provide for avertical as well as a horizontal locking and which allow that two ofsuch floor panels can be coupled to each other by means of an anglingmovement. Floor panels with such a combination of coupling parts offerthe advantage that they can be easily installed successively in rows,simply by coupling each new floor panel to be installed to the precedingrow of floor panels by means of the angling movement and by providingfor, when angling it down, that such floor panel simultaneously alsoengages in an already installed preceding floor panel of the same row.Thus, the installation of such floor panel only requires an angling andputting-down movement, which is a particularly user-friendlyinstallation technique.

A disadvantage of floor panels with such coupling parts consists in thatdue to the fact that there is no locking in vertical direction, heightdifferences between the coupled floor panels may arise at the topsurface. Thus, for example, such floor panels in a first or last row ofa floor covering may turn back upward from their flat position, if theyare not held down by a skirting board or the like. Even if such floorpanels are provided with a “drop-in” system at only one pair of sides,while being locked in horizontal as well as vertical directions at theirother pair of sides in respect to adjacent floor panels, heightdifferences may occur between adjacent floor panels at the sides coupledby the “drop-in” system, amongst others, when two adjacent floor panelsare loaded differently, or when one floor panel should warp and bendsomewhat in respect to the other.

Couplings of said second kind, also named “push-lock” systems, try toremedy the aforementioned disadvantage by also providing a verticallocking. Such so-called “push-lock” systems may be divided into twodifferent categories, namely one-piece embodiments and embodimentscomprising a separate locking element, which is made as an insert,whether or not fixedly attached to the actual floor panel.

One-piece embodiments are known, amongst others, from the patentdocuments DE 29924454, DE 20008708, DE 20112474, DE 102004001363, DE102004055951, EP 1,282,752 and EP 1,350,904. The known one-pieceembodiments have the disadvantage that they are working relatively stiffand a good joining of two floor panels can not always be guaranteed.

Embodiments comprising a separate locking element which assists in avertical and possibly also horizontal locking between two coupled floorpanels, are known, amongst others, from the patent documents DE202007000310, DE 10200401363, DE 102005002297, EP 1,159,497, EP1,415,056B1, EP 1,818,478, WO 2004/079130, WO 2005/054599, WO2006/043893, WO 2006/104436, WO 2007/008139, WO 2007/079845 and SE515324. The use of a separate locking element offers the advantage thatthe material thereof is independent of the actual floor panel and thuscan be chosen in an optimum manner in function of the application.Thereby, such inserts may be made of synthetic material or metal,whereby relatively sturdy, however, still easily movable lockingportions can be realized, which, with a minimum contact surface, cantake up relatively large forces.

SUMMARY OF THE DISCLOSURE

The present invention relates to floor panels which are equipped with a“push-lock” system of the last-mentioned category, in other words, whichcomprise a whether or not fixedly attached, however, separately realizedinsert. The aim of the invention consists in a further optimization ofthese “push-lock” systems in floor panels. These improvementssubstantially consist of seven aspects, which will be discussed in thefollowing.

The first five aspects are specifically connected to floor panels of thetype:

-   -   which comprises, at least at two opposite sides, coupling parts        with which two of such floor panels can be coupled to each        other;    -   wherein these coupling parts form a horizontally active locking        system and a vertically active locking system;    -   wherein the horizontally active locking system comprises a male        part and a female part, which allow that two of such floor        panels can be connected to each other at the aforementioned        sides by providing one of these floor panels with the pertaining        male part, by means of a downward movement, in the female part        of the other floor panel;    -   wherein the vertically active locking system comprises a locking        element, which is provided in the form of an insert in one of        the sides concerned;    -   wherein this locking element comprises at least a pivotable        lock-up body; and    -   wherein the lock-up body, at one extremity, forms a stop-forming        locking portion, which can cooperate with a locking portion of a        similar coupled floor panel.

Floor panels of this type are known, amongst others, from the FIGS. 5-7,8 and 9-11 of the aforementioned EP 1,415,056B1. In these knownembodiments, the locking portion realized in the form of an insertconsists of a synthetic material strip with an elastically bendable lip,which, during its bending, functions as a pivotable lock-up body. Theseknown embodiments show the advantage that with a relatively simpleconstruction, a so-called “push-lock” connection can be realized whichis active over the entire length of the synthetic material strip.However, practice has shown that this known embodiment is not alwaysfunctioning smoothly and that tolerances in a realized couplingsometimes are difficult to keep under control.

According to its first five aspects, the present invention aims at floorpanels of the aforementioned specific type, which are further improvedin respect to the aforementioned known embodiments. Thus, theseimprovements substantially consist in five aspects, which can be appliedseparately or in any imaginable combination.

To this aim, the invention according to a first aspect relates to afloor panel of the above-mentioned specific type, with thecharacteristic that the pivotable lock-up body, opposite from theextremity forming the locking portion, comprises a support portion,which is rotatable against a support surface pertaining to the floorpanel concerned, and more particularly is rotatable in a seat. As thelock-up body is provided with a support portion which is rotatableagainst a support surface, and more particularly is rotatable in a seat,the rotational movement of the lock-up body is defined better than inthe known embodiments, and a more precise coupling can be provided than,for example, in the case of an embodiment according to FIGS. 5-7, 8 and9-11 of said EP 1,415,056B1. In this known embodiment, the pivotablelock-up body in fact is realized as a prolongation of an attachmentportion, whereby the hinge function occurs in the material of theinsert, and the precise rotational movement is difficult to predict,which may lead to a less optimum functioning.

According to a second independent aspect, the invention relates to afloor panel of the above-mentioned specific type, with thecharacteristic that the pivotable lock-up body, opposite to theextremity forming the locking portion, comprises a support portion andthat the lock-up body, between the locking portion and the supportportion, in itself is free from hinge portions and bending sections. Asthe lock-up body is free from hinge portions and bending sections,possible influences thereof on the shape and length of the lock-up bodyare excluded and a fixed useful length of the lock-up body can beguaranteed, such that, amongst others, small production tolerances canbe maintained, allowing precise couplings. In connection therewith, itis thus preferred that the lock-up body is performed as a rigid element.

According to a third independent aspect, the invention relates to afloor panel of the above-mentioned specific type, with thecharacteristic that the pivotable lock-up body, opposite to theextremity forming the locking portion, comprises a support portion inthe form of a free extremity, which, at least in vertical direction, ispositively supported by a support portion pertaining to the floor panel.As the support portion is made as a free extremity, it does notexperience influences from adjacent material portions in its supportportion, which is beneficial for a smooth hinge motion of the lock-upbody. By a free extremity is substantially meant that this simply ismade as a protruding leg, without any further parts being attachedthereto.

According to a fourth independent aspect, the invention relates to afloor panel of the above-mentioned specific type, with thecharacteristic that the lock-up body is rotatable around a rotationpoint, support point, respectively, and that the locking elementcomprises a press-on portion engaging at the lock-up body at a distancefrom the rotation point, support point, respectively. Thereby, it ispossible to exert a suitable force with the press-on element against thepivotable lock-up body, even if this press-on element as such isrelatively weak.

According to a fifth independent aspect, the invention relates to afloor panel of the above-mentioned specific type, with thecharacteristic that the vertically active locking system comprises atensioning system which is formed by a cam surface formed at theextremity of the locking portion of the lock-up body, which cam surface,in coupled condition, provides for a wedge effect against the oppositelocking portion of the coupled floor panel. Due to such configuration,the lock-up body, in coupled condition, always will settle well underthe locking portion of the other floor panel. Due to small movementsoccurring when the floor panels are being walked on, the lock-up body,due to the wedge effect, will crawl farther under the locking portion ofthe other floor panel, whereby an even sturdier coupling is obtained. Itis noted that this fifth aspect can be applied for all forms ofrotatable locking portions, and thus, for example, also for embodiments,such as known from EP 1,415,056B1.

According to a sixth independent aspect, the invention relates to afloor panel comprising, at least at two opposite sides, coupling partswith which two of such floor panels can be coupled to each other;wherein these coupling parts form a horizontally active locking systemand a vertically active locking system; wherein the horizontally activelocking system comprises a male part and a female part, which allow toconnect two of such floor panels to each other at the aforementionedsides by providing one of these floor panels with the pertaining malepart, by means of a downward movement, in the female part of the otherfloor panel; and wherein the vertically active locking system comprisesa locking element, which is provided in the form of an insert in one ofthe sides concerned; with the characteristic that the locking elementconsists of a co-extruded synthetic material strip provided in a recess,which strip, viewed in cross-section, is composed of two or more zonesconsisting of synthetic materials with different features. In otherwords, there are at least two zones of materials with different materialcharacteristics. However, it is not excluded that certain zones do havethe same material characteristics.

The use of such co-extruded synthetic material strip offers theadvantage that the features can be selected depending on the functionwhich certain parts of such strip have to fulfill. For example, certainparts, which have to exert a pressure force or tension force, can berealized in a rather elastic synthetic material, whereas parts whichhave to take up forces in an immobile manner, then better consist of ahard synthetic material. Preferably, then also use is made of syntheticmaterials with different flexibility, elasticity, respectively. Also,flexible synthetic materials may be applied in order to realize movableconnections among different parts of the strip. According to stillanother possibility, by means of the coextrusion zones are realizedwhich can provide for a better sealing, or which offer increasedfriction resistance. Summarized, it is so that the different syntheticmaterials are applied in function of the desired movability and/or thedesired compressibility and/or the desired sealing effect.

It is clear that the sixth aspect extends to all “push lock” systemswhich apply a separate locking element which is provided or is to beprovided in a recess in the edge of a floor panel, and is notexclusively restricted to locking elements with a pivotable lock-upbody.

According to a seventh independent aspect, the invention relates to afloor panel comprising, at least at two opposite sides, coupling partswith which two of such floor panels can be coupled to each other;wherein these coupling parts form a horizontally active locking systemand a vertically active locking system; wherein the horizontally activelocking system has a male part and a female part, which allow to connecttwo of such floor panels to each other at the aforementioned sides byproviding one of these floor panels with the pertaining male part, bymeans of a downward movement, in the female part of the other floorpanel; wherein the vertically active locking system comprises a lockingelement, which is provided in the form of an insert in one of the sidesconcerned; with the characteristic that the locking element consists ofa synthetic material strip provided in a recess, which strip, in thecoupled condition of two floor panels, comes into contact with bothfloor panels and thereby forms a seal, wherein between the upper side ofthe floor panel and the synthetic material strip also a seal is presentat the panel edges. The importance and advantage of this aspect willbecome clear from the following detailed description.

It is noted that all forms of combinations of the aforementioned sevenaspects are possible.

Various advantageous dependent characteristics further will be describedby means of the embodiments represented in the figures. All thesedependent characteristics do not necessarily have to be applied in themutual combinations as shown in the figures. Each characteristic can becombined as such with one of the independent aspects; such inasmuch assuch dependent characteristic is not inconsistent with thecharacteristics of the respective independent aspect itself.

It is noted that the present invention preferably is applied forembodiments where the locking element, made as an insert, substantially,and still better exclusively, serves as a locking element assisting inthe vertical locking and, thus, not in the horizontal locking. Thehorizontal locking preferably exclusively is performed by means ofparts, such as the aforementioned male part and female part, which aremade from the actual panel material, more particularly are mechanicallyformed therefrom. More particularly, the invention preferably relates toembodiments wherein the insert is produced separately and then ismounted in an edge of an actual floor panel, whether or not in a fixedmanner.

More particularly, it is noted that the invention preferably is appliedin embodiments where said locking element provides exclusively for anupward blockage, which means that this blockage prevents that the malepart can come loose from the female element in an upward direction,whereas blockages in the other directions, thus, in downward directionand in horizontal direction, are obtained by the design of the paneledges themselves, in other words, by the coupling parts mechanicallyformed in the material of the panel.

Preferably, the invention relates to embodiments wherein at least thelock-up body, and still better even the entire locking element made asan insert, is realized relatively local, which more particularly meansthat it is only present between a first and a second horizontal level,of which the first horizontal level is situated at a distance beneaththe upper side of the coupled floor panels, whereas the secondhorizontal level is situated lower than the first, however, higher thanthe lowermost point of the male part. Subsidiary thereto, it is,however, still preferred that said lock-up element extends over a heightwhich is at least 40% and still better at least 50% of the heightdifference between the upper side of such coupled floor panels and thelowermost point of the male part. Using at least 40%, at least 50%,respectively, of this height in combination with said location betweensaid first and second level offers various advantages. An advantage ofembodiments fulfilling this consists in that a good compromise isachieved between sufficient compactness from the point of view of thepossibility of a smooth application in the edge of a floor panel andfrom the point of view of the costs, on the one hand, and sufficientextent in order to optimize construction and shape of the lockingelement, on the other hand. Still another advantage in respect to theknown embodiments of floor panels with a comparable total thickness,however, wherein the height of the lock-up body does not fulfill saidratio of at least 40%, is that, at least in the case of a pivotablelock-up body, a smaller rotation of this lock-up body already results ina relatively large deviation at the free extremity, whereby a goodlocking can be obtained in a smooth manner. As a consequence thereof,mostly a locked condition can be realized in which the lock-up elementis standing relatively upright and extends under an angle with thevertical which is considerably smaller than 45%, whereby the lock-upelement offers a particularly solid locking. This also allows workingwith a lock-up body of which the protruding exterior side is standingrelatively upright, whereby this body during coupling can be pushedaside more smoothly by another panel. As the lock-up element in thelocked condition is standing very upright, it is also obtained that thecontact points of the lock-up body with the connected floor panels arelocated close to the panel edges, which is beneficial for a goodconnection.

The present invention relates to embodiments wherein said lockingelement is integrated in the male part, as well as to embodimentswherein said element is integrated in the female part. In the case ofintegration in the male part, the locking element preferably is situatedin the distal side of this part, although integration in another side isnot excluded. In the case of integration in the female part, the lockingelement preferably is situated at the proximal side, althoughintegration in another side is not excluded.

Preferably, the coupling parts of the floor panels of the invention alsoare configured such that they can be uncoupled by means of a pivotingmovement, irrespectively according to which of the aforementionedaspects they are realized. According to a particular embodiment, thecoupling parts further are configured such that coupling by means of anangling movement is possible, too.

According to another embodiment, the male and the female part of saidfloor panels are configured such that said floor panels can be broughtinto each other at the sides concerned by shifting them towards eachother, preferably even such that this is possible by moving them towardseach other in a substantially same plane, for example, by shifting apanel towards another over an underlying surface. The locking thenpreferably takes place by means of a snap-on connection, wherein thehook-shaped part of the female part bends elastically during joining.

According to still another variant, said floor panels are realized suchat the sides concerned that, apart from locking by means of a downwardmovement, also a locking by shifting the floor panels towards eachother, as well as a locking and/or unlocking by angling the floor panelsin mutual respect is possible.

It is noted that the configuration allowing that two floor panels at thesame edges can be joined by means of a downward movement, thus,according to the “push-lock” principle, as well as by a mutual shiftingin the same plane, thus, according to the principle of “snap action bymeans of shifting in the same plane”, also more generally forms aparticularity, without this combination necessarily having to becombined with one of said seven aspects. Due to this, the invention,according to an eighth aspect, thus also relates to a floor panelcomprising, at least at two opposite sides, coupling parts with whichtwo of such floor panels can be coupled to each other; wherein thesecoupling parts form a horizontally active locking system and avertically active locking system; wherein the horizontally activelocking system has a male part and a female part, which allow that twoof such floor panels can be connected to each other at said sides byproviding one of these floor panels with the pertaining male part, bymeans of a downward movement, in the female part of the other floorpanel; wherein the vertically active locking system comprises a lockingelement, which is provided in the form of an insert in one of the sidesconcerned; wherein this locking element comprises a lip-shaped lock-upbody; and wherein the lock-up body, at one extremity, forms astop-forming locking portion, which can cooperate with a locking portionof a similar coupled floor panel; characterized in that the male partand the female part are configured such that two of such floor panelscan be joined into each other at the sides concerned by shifting themwith the sides concerned towards each other in the same plane. Hereby,the advantage is created that the installation comfort of such floorpanels is considerably increased, as connecting by means of the downwardmovement allows for a rapid assembly, whereas the possibility ofcoupling together by shifting the floor panels towards each other offersthe advantage that they can also be coupled to each other at locationswhere no downward movement is possible and solely coupling by shiftingis possible, such as, for example, in the case that a floor panelpartially must be provided underneath an overhanging element, such as adoor frame, and from this position still has to be coupled to anotherfloor panel.

It is clear that the invention also relates to floor panels combiningthe eighth aspect with one or more of the preceding aspects.

Floor panels meeting the eighth aspect preferably also show one or moreof the following characteristics:

-   -   the coupling parts concerned are performed at the aforementioned        sides such, that they allow a locking and/or unlocking of two of        such floor panels in mutual respect by mutually angling them        into each other, out of each other, respectively;    -   in free condition, the lip-shaped lock-up body protrudes outward        in an inclined manner;    -   the lock-up body is provided in the proximal side of the female        part;    -   the female part and the male part comprise contact surfaces at        their distal extremities, said surfaces being performed upwardly        inclined in distal direction;    -   the lip-shaped lock-up body is a pivotable body.

According to a particularly preferred embodiment, the floor panels ofthe eighth aspect relate to rectangular, either oblong or square,panels, and a pair of opposite sides of said coupling parts is providedaccording to the eighth effect, whereas the other, second pair ofopposite sides comprises coupling parts, which also can provide for avertical and horizontal locking, of which kind whatsoever, however,which still allow that two of such floor panels can be joined into eachother at the last-mentioned sides by substantially shifting them withthe sides concerned towards each other in the same plane. Thiscombination of possibilities offers an even higher comfort ofinstallation in difficult situations. According to an additionalpreferred characteristic, the coupling parts at the second pair ofopposite sides also are configured such that they allow angling thefloor panels in and out of each other. Examples of such coupling partsare widely known from the state of the art, for example, from FIG. 23 ofWO 97/47834.

According to still another particular embodiment, the coupling parts ofthe eighth aspect are applied at both pairs of sides.

Further, the invention according to a ninth aspect also relates to afloor panel comprising, at least at two opposite sides, coupling partswith which two of such floor panels can be coupled to each other at therespective edges; wherein these coupling parts form a horizontallyactive locking system and a vertically active locking system; wherein atleast one of the locking systems comprises a locking element, which isprovided in the form of a separate insert at one of the edges concerned;wherein this locking element comprises at least a movable lock-up body;and wherein the lock-up body, at one extremity, forms a stop-forminglocking portion, which can cooperate with a locking portion of a similarcoupled floor panel; with the characteristic that the locking elementconsists of a synthetic material strip which, viewed in cross-section,is composed of at least two zones of materials with different materialcharacteristics. By making use of a separate insert formed of differentmaterials, the advantage is created that the different portions of theinsert can be optimized in function of their purpose. So, for example,may the lock-up body be realized relatively rigid in order to be able toadequately withstand occurring forces, whereas one or more otherportions, which must provide the movability of the lock-up body, then assuch are realized relatively flexible.

Preferably, the floor panel according to the ninth aspect further ischaracterized in that the lock-up body is attached directly orindirectly to a material part pertaining to the locking element or ismade in one piece therewith, which allows an elastic movement of thelock-up body, wherein this material part consists of a material which assuch is more flexible and bendable than the material of which thelock-up body basically is formed.

According to still another preferred characteristic, the aforementionedmaterial part is performed as a local hinge part, with the advantagethat a very precisely defined pivoting movement is obtained.

Herein, it is preferred that said material part forms a connectionbetween the lock-up body and an attachment portion, wherein the lock-upbody and the attachment portion consist of material which is lessflexible than said material part. In this manner, it is obtained that anadequate locking is created by means of the relatively rigid lock-upbody, whereas by means of the relatively rigid attachment portion astable positioning of the locking element in a recess in the edge of thefloor panel concerned is possible.

In a preferred embodiment of the ninth aspect of the invention, theattachment portion consists of an attachment body which, viewed incross-section, extends in a flat or rather flat direction, which meanssubstantially in the plane of the floor panel, which attachment body isprovided in a recess. Such attachment portion allows an adequateattachment, also when the invention is applied in relatively thin floorpanels. Another advantage is that by somewhat altering the directionwith which this attachment portion is applied in the floor panel,different functioning characteristics can be obtained and the engineerin this manner can provide for an optimization.

Also according to the ninth aspect, the floor panel will becharacterized in that the lock-up body can be elastically angled outwith an extremity; that the lock-up body, globally seen, forms an anglewith the attachment portion; that the lock-up body, with the extremitysituated opposite to the extremity which can be angled out, protrudes upto beyond the attachment portion; that said material part makes aconnection between said extremity protruding beyond the attachmentportion and an adjacent portion of the actual attachment portion; andthat at the location where the lock-up body passes along the attachmentportion, the distance between the lock-up body and the attachmentportion is smaller than the distance from the protruding extremity ofthe lock-up body to the attachment portion. As will become clear fromthe further description, this offers various advantages.

In the most preferred embodiment, the locking element of the ninthaspect of the invention is formed by means of coextrusion.

The ninth aspect is particularly useful with floor panels of the typewhich is characterized in that the horizontally active locking systemcomprises a male part and a female part, which allow that two of suchfloor panels can be connected to each other at said sides by providingone of these floor panels with the pertaining male part, by a downwardmovement, in the female part of the other floor panel, in other words,floor panels of the so-called push-lock type. However, it is noted thatthe ninth aspect is not restricted to this type of floor panels and inprinciple can be applied for each type of coupling for floor panelswherein a horizontally active locking system and vertically activelocking system are applied, wherein in one or the other way a separatelocking system is integrated. So, for example, it is possible tointegrate the ninth aspect in strip-shaped locking elements of the typesuch as known from WO 2006/104436, more particularly FIGS. 9c, 9e and 9f.

It is clear that the characteristics of the ninth aspect also can becombined with the characteristics from the first eight aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

With the intention of better showing the characteristics of theinvention, hereafter, as an example without any limitative character,several preferred embodiments are described, with reference to theaccompanying figures, wherein:

FIG. 1 schematically and in top plan view represents a floor panelaccording to the invention;

FIG. 2, at a larger scale, represents a cross-section according to lineII-II in FIG. 1;

FIG. 3 in cross-section represents two floor panels, which are madeaccording to FIG. 2, in coupled condition;

FIGS. 4 and 5 represent the floor panels from FIG. 3 in two differentsteps during the joining;

FIG. 6, at a larger scale, represents the locking element applied in theembodiment of FIGS. 2 to 5;

FIG. 7, at a larger scale, represents the portion indicated by F7 inFIG. 2;

FIG. 8 schematically represents how the locking element of FIG. 7 can bemounted in a floor panel;

FIG. 9 represents the locking element of FIG. 6 in cross-section and ata strongly enlarged scale;

FIG. 10, at a still larger scale, represents the uppermost extremity ofthe locking element of FIG. 9, together with a locking portion withwhich it comes into contact;

FIGS. 11 and 12 represent two variants;

FIGS. 13 and 14 represent two practical embodiments;

FIGS. 15 and 16 represent a particular embodiment;

FIG. 17 represents still another embodiment of the invention;

FIGS. 18 and 19, at a larger scale, represent the portions indicated byF18 and F19 in FIG. 17;

FIG. 20 represents a particular fashion of coupling together two floorpanels made according to FIG. 17;

FIGS. 21 to 24 represent another four embodiments of the invention;

FIG. 25 represents a number of floor panels which are realized accordingto the invention;

FIG. 26, at a larger scale, represents the portion indicated by F26 inFIG. 25;

FIGS. 27 and 28 in cross-section represent another two particularembodiments of the invention;

FIGS. 29 and 30 represent another two embodiments of the invention;

FIG. 31 represents a schematic top view of floor panels, which arecoupled to each other according to FIG. 25;

FIG. 32, in cross-section, represents still another embodiment of theinvention;

FIG. 33 in cross-section represents still another embodiment of theinvention;

FIG. 34, at a larger scale, represents the portion indicated by F34 inFIG. 33;

FIGS. 35 to 37 represent the part from FIG. 34 for various conditionsduring coupling of two floor panels;

FIG. 38 schematically represents how a locking element, made as aninsert, according to the invention can be attached in the edge of afloor panel;

FIGS. 39 to 41, at a larger scale, represent cross-sections according tolines XXXIX-XXXIX, XL-XL and XLI-XLI, respectively, in FIG. 38;

FIG. 42 in cross-section represents still another embodiment of atechnique according to the invention, according to which a lockingelement made as an insert can be attached in the edge of a floor panel;

FIG. 43 represents a schematized cross-section according to lineXLIII-XLIII in FIG. 42.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

As represented in FIGS. 1 to 5, the invention relates to a floor panel 1comprising, at least at two opposite sides 2-3, coupling parts 4-5, withwhich two of such floor panels 1 can be coupled to each other.

As becomes clear from the coupled condition of FIG. 3, these couplingparts 4-5 comprise a horizontally active locking system 6 and avertically active locking system 7. The horizontally active lockingsystem 6 comprises a male part 8 and a female part 9, which allow toconnect two of such floor panels 1 to each other at the aforementionedsides 2-3 by providing one of these floor panels 1 with the pertainingmale part 8, by means of a downward movement M, in the female part 9 ofthe other floor panel, which movement M is illustrated by means of twodifferent positions in the FIGS. 4 and 5.

The male part 8 is formed by a downward-directed extremity of ahook-shaped part 10, whereas the female part 9 consists of a seat formedby means of an upward-directed hook-shaped part 11.

The vertically active locking system 7 comprises a locking element 12,which, in the form of an insert, is provided in one of the sidesconcerned, in this case, the side 2, more particularly in a recess 13provided to this aim. For clarification, the locking element 12, or inother words, thus, the insert, is illustrated in separate condition inFIG. 6. As can be seen in this figure, this locking element 12preferably is made as a strip. It is clear that this strip preferablyextends over the entire or almost entire length of the side 2.

Preferably, this strip consists of synthetic material, however, the useof other materials to this aim is not excluded. Further, it is preferredthat the strip has a continuous cross-section over its entire length,which renders it simple to manufacture. In the case of a syntheticmaterial strip, preferably use is made of PVC.

The enlarged view of FIG. 7 shows in greater detail how the strip isattached in the recess 13, which will be discussed further on.

In the represented example, the locking element 12 is composed at leastof a pivotable lock-up body 14 and a press-on portion 15. In theembodiment of FIG. 6, the lock-up body 14 consists of the entire uprightpart, whereas the press-on portion 15 is formed by the portioninclinedly directed away.

The extremity 16 of the lock-up body 14, which can be rotated out,functions as a stop-forming locking portion 17, which can cooperate witha locking portion 18 of a similar coupled floor panel 1. Herein, thelocking portion 18 preferably is formed by a portion defining astop-forming surface 19, which for this purpose is present in the side 3and preferably is mechanically provided in the core of the floor panel1. The functioning of the vertically active locking system can simply bededuced from the figures and relies on the principle that, asrepresented in FIGS. 4 and 5, when moving the floor panel concerneddownward, the lock-up body 14 is elastically folded inward by thecontact with the edge of the other floor panel, after which, as soon asthe floor panels have arrived in the same plane, the lock-up elementrotates back outward in order to position itself beneath the lockingportion 18, such that the coupled condition of FIG. 3 is created.

In accordance with the first aspect of the invention, the pivotablelock-up body 14, opposite from the extremity 16 forming the lockingportion 17, comprises a support portion 20, which is rotatable against asupport surface 21 pertaining to the floor panel 1 concerned, and moreparticularly in a seat 22. By the support portion 20 in the embodimentof FIGS. 2 to 10 thus the lowermost extremity 23 of the lock-up body 14is meant.

Further, the lock-up body 14 as such, between the locking portion 17 andthe support portion 20, in other words, between its extremities 16 and23, is free from hinge portions and bending sections, such in accordancewith the second aspect of the invention. To this aim, thus, the lock-upbody 14 is made relatively thick and preferably forms a rigid body,which means that the lock-up body 14 can not undergo noticeabledeformations between its extremities when pressures are exertedhereupon, which usually may arise with “push-lock” couplings.

In accordance with the third aspect of the invention, the supportportion 20 in the represented embodiment is made as a free extremity,which is positively supported at least in vertical direction by asupport portion 24, more particularly support surface 21, pertaining tothe floor panel 1.

As can be clearly seen in FIGS. 3 and 7, the support portion 20 of thelock-up body 14 preferably even is supported in two directions, at leastin a coupled condition of two floor panels 1, namely in verticaldirection V, in this case, thus, downward, as well as in proximaldirection P in respect to the floor panel 1, this latter by means of thelateral wall 25 of the seat 22.

In the represented example of FIGS. 1 to 10, the floor panel 1 alsocomprises a stop-forming part 26, which, in a distal direction D inrespect to the floor panel 1, forms a blockage for the support portion20 or, thus, for the extremity 23 of the lock-up body 14. Thereby, aproper seat 22 can be formed, as a result of which the support portion20 is sitting enclosed at three sides. In this manner, the seat canfunction as a rather precisely defined hinge point.

Generally, it can be stated that the locking element 12 preferablyconsists of a strip which is attached in a recess, in the representedexample, thus, the recess 13, in the floor panel 1 and that attachmentprovisions are present therein, retaining the strip in the recess. Moreparticularly, it is preferred that the strip is snap-fitted in therecess and/or is sitting enclosed therein due to the design, whichprinciple also has been applied in the embodiment of FIGS. 1 to 10. Asindicated in FIG. 7, the opening A of the recess is smaller than thelargest dimension B of the strip, with the consequence that the latterautomatically is retained in the recess 13.

It is noted that other techniques for attaching or retaining such stripin the recess are possible, for example, by gluing, clamping or thelike. A number of advantages are described in the following.

As schematically illustrated in FIG. 8, the strip or, thus, the lockingelement 12 simply can be provided at a floor panel 1 by pressing it intothe recess 13, for example, by means of a press-on portion or slidingblock 27. Due to the exerted pressure, the strip is deformed and fitsthrough opening A, after which it regains its original shape and becomesenclosed in the recess. More particularly, hereby the press-on portion15 is bent in the manner as represented, in order to finally bounce intoplace.

The embodiment of FIGS. 1 to 10 also applies the fourth aspect of theinvention, namely in that the lock-up body 14 is rotatable around arotation point, support point, respectively, and the press-on portion15, at a distance from the rotation point, and more particularly at adistance D1 from the actual support point, engages at the lock-up body14. It is noted that by a “point”, also a “zone” can be intended. Thus,a “support point” also may extend over a “zone”.

As represented, the press-on portion 15 preferably consists at least,viewed in cross-section, of a leg adjoining to the rear side of thelock-up body 14, which leg, in free condition, extends obliquely inrespect to the lock-up body 14, such from a location P1 situated betweenthe two extremities of the lock-up body. Preferably, this leg alsoglobally extends under an angle A1 of less than 70 degrees in respect tothe portion 28 of the lock-up body 14, which portion extends from saidlocation P1 towards the locking portion 17.

The press-on portion 15 preferably consists of an elastic material, andmore particularly a material, which as such is more flexible than thematerial of the lock-up body 14. Preferably, this is also syntheticmaterial, and in the most preferred embodiment, the press-on portion 15is made in one piece with the lock-up body 14 by means of coextrusion.In the enlarged views of FIGS. 6 and 9, the co-extruded materials arerepresented with different shading.

Generally, it is noted that a locking element 12 in cross-section canonly be of small dimensions, in view of the fact that it must beintegrated in the edge of floor panels having in practice a thicknesswhich usually is less than 2 cm and in many cases is even less than 1cm. Thus, the space then available for the locking element 12 often onlylies in the order of magnitude of 5 millimeters or less. When with suchsmall dimensions different flexibilities must be incorporated into thelocking element, the possibilities thus also are limited when onedesires to perform this in a traditional manner by working withdifferent thicknesses. By now using coextrusion according to theinvention, a broader range of possibilities is created for incorporatingdifferent flexibilities, and thus also a different elasticity, dependingon the intended effect.

The co-extruded materials may consist of the same or similar basicmaterial and, for example, differ from each other only in that certaincomponents are added to the one material, or certain components arepresent to a larger extent. In a practical embodiment, the entire stripwill consist of PVC, however, the more flexible portion will be formedof PVC to which a larger quantity of plasticizer is added.

Also the location of the transition T between the co-extruded materialsis of importance. So, for example, this transition T, in the embodimentof FIGS. 1 to 10, preferably is situated at a distance X from thelock-up body. Thereby, a more rigid guiding portion remains present atthe basis of the press-on portion 1, which promotes the snap-on effectrepresented in FIG. 8.

In the embodiment of FIGS. 1 to 10, the press-on portion 15, viewed incross-section, consists of only one leg.

In the embodiment of FIGS. 1 to 10, a tensioning system 29 is integratedin the vertically active locking system, which tensioning systemprovides for that a good locking is created when the lock-up body 14 isangled out. By a tensioning system, here a system is intended which,when angling out the lock-up body 14, additionally effects the approachamong the locking portions 17 and 18.

As made clear in the larger representations of FIGS. 9 and 10, in theembodiment of FIGS. 1 to 10 to this aim use is made of a cam surface 30formed at the extremity 16 of the lock-up body 14, which cam surface, incoupled condition, provides a wedge effect against the opposite lockingportion 18 of the coupled floor panel 1.

As indicated in FIG. 9, the cam surface 30, which consists at least ofan effective contact zone 31 and possibly an entry zone 32, preferablyextends over a width B1 of at least 60% of the total width B2 of thelock-up body 14, which allows providing a gradual transition, whichpromotes a good wedge effect. Indeed, the entry zone 32 preferably issomewhat steeper than the contact zone 31 and is intended to provide forthat the lock-up body 14 initially always will get smoothly beneath thesurface 19.

Herein, the cam surface 30 preferably extends such that, as representedin FIGS. 9 and 10, according to a direction R, from the most outwardlysituated edge 33 to the most inwardly situated edge 34, the cam surface30 shows an increasing elevation E, such that the effective length ofthe lock-up body 14 increases for the successive points of the camsurface according to the direction R. Herein, the effective length isthe distance between the locations where the lock-up body comes intocontact at the top and at the bottom.

The cam surface 30 and the surface 19 situated opposite thereofpreferably are performed such that a displacement of the lock-up body 14as a consequence of tolerance differences results in a smaller or nodisplacement of the contact zone, more particularly the contact point,between both locking portions 17 and 18. Preferably, therein the amountof the displacement of the contact zone or the contact point is lessthan 50% of the size of the displacement of the cam surface 30. This isillustrated in the following by means of FIG. 10. Herein, a firstcondition with a contact point in position C1 is represented in solidline. When, due to settling, the surface 19 comes to lie somewhathigher, a condition is created such as represented in dashed line,wherein the contact point is displaced from a position C1 to C2, andsuch according to the invention with a displacement V1, which isnoticeably smaller than the displacement V2 of the lock-up body 14. Theadvantage herein is that at all times, the displacement V2 is small, andit can be guaranteed that the contact always takes place within acertain distance D2 from the upper edges of the floor panels 1 and a toofar outward rotation, which might lead to a weak connection, isexcluded. With tolerance differences, too, the same effect occurs. Afirst pair of floor panels may come into contact, for example, asrepresented in solid line, whereas another pair, due to tolerancedifferences, comes into contact as represented in dashed line. Due to acam shape according to the invention, it is then prevented that in thesecond case the contact point C2 would be situated too far from theedges of the floor panels.

It is noted that, as represented in the figures, the locking portion 17of the lock-up body 14 preferably is performed in the form of abroadened extremity of the lock-up body 14, due to which more space isoffered for realizing a desired cam surface 30.

The inclinations of the cam surface 30 and the surface 19 cooperatingtherewith preferably are realized such that they always define a tangentline L1-L2 in their contact zone, contact point C1-C2, respectively, theinclination angles of which with the horizontal, of which solely one isindicated in FIG. 10 by A2, are less than 35 degrees.

FIGS. 11 and 12 show that the contact point C can also be displaced bythe selection of the shape of the surface 19 with which the lock-up body14 cooperates in coupled condition. It is noted that in coupledcondition the connection line L3 between the contact point C, or themiddle of the contact zone when the contact is wider than a point, and apoint where the lock-up body 14 is supported, is as vertical aspossible, as then, amongst others, horizontal force components, whichmight force the lock-up body back, remain limited. In this respect, itis also preferred that the distance D3, at which the contact C, thecenter op the contact zone, respectively, is situated from the planewhere the floor panels 1 fit against each other, is smaller than 1 mmand still better is smaller than 0.8 mm.

As represented in FIGS. 2 and 7, the locking element 12 and the recess13 are performed such that this locking element 12, in the free,uncoupled condition of the floor panel 1 concerned, is sitting at leastpartially with its locking portion 17 within the recess 13. This offers,amongst others, the advantage that the strip, of which this lockingelement consists, when two floor panels 1 are joined into each other bymeans of a downward movement, in principle never can be pulled out ofits seat by friction forces or for any other cause, due to which thegood functioning might be disturbed.

It is clear that the coupling according to the invention can be appliedin combination with any floor panel 1.

FIG. 13 shows the application of the embodiment represented in FIGS. 1to 10 in so-called prefabricated parquet, more particularly in so-called“engineered wood”. In this example, this relates to floor panels 1 whichare constructed from a core 38 composed of strips 35-36-37, a top layer39 of wood, as well as a backing layer 40 of wood. The top layer 39consists of wood of a good quality, which functions as a visibledecorative layer. The backing layer 39 may consist of a cheaper kind ofwood. The strips 35 preferably also consist of a cheaper, for example,soft kind of wood. However, it is preferred that at the extremities ofthe floor panels 1 strips 37-38 of a material are applied which isrelatively sturdy and suited for providing the desired profile shapestherein, for example, milling them therein. In a practical embodiment,these strips 37-38 consist of MDF (Medium Density Fiberboard) or HDF(High Density Fiberboard). It is clear that the invention can also beapplied in combination with other forms of “engineered wood”, forexample, wherein the core consists of a single continuous MDF/HDF boardor of a plywood board.

FIG. 14 represents an application in a laminate floor panel, in thiscase a so-called DPL (Direct Pressure Laminate), which, in a knownmanner, consists of a core 41, for example, of MDF or HDF, a top layer42 on the basis of one or more resin-impregnated layers, for example, aprinted decor layer 43 and a so-called overlay 44, as well as a backinglayer 45, which also consists of one or more resin-impregnated layers,wherein the whole is consolidated under heat and pressure.

Applications in other floor panels 1 are not excluded.

FIGS. 15 and 16 represent a particular embodiment, wherein in the sideof the floor panel 1 situated opposite to the lock-up body 14, a recess46 is provided, wherein, as can be seen in FIG. 16, in the longitudinaldirection of the edges a rod 47 or the like can be introduced betweenthe floor panels 1, in such a manner that the lock-up body 14 is pushedback and the floor panel concerned can be lifted and thus can beuncoupled.

FIG. 17 represents a variant of the invention, which differs from theabove-described embodiment in a number of ways. So, for example, doesthe pivotable lock-up body 14, next to the extremity 23 along which itis pivotable, comprise a tensioning system 48, which in this example, asillustrated in the enlarged view of FIG. 18, substantially consists of acam 49 realized at said extremity 23, which cam, when the lock-up body14 is being pivoted outward, also subjects this lock-up body 14 to anaxial displacement V3 in the direction of the locking portion 17. It isclear that the cam 49 to this aim must be realized with a suitableelevation, which can be determined by those skilled in art in functionof the desired effect. In FIG. 18, the elevation is illustrated by thedistances D4 and D5, wherein D5 is larger than D4. The axialdisplacement V3 contributes to that the lock-up body 14, duringcoupling, initially can pivot outward in a smooth manner, however, assoon as it is partially pivoted out, rather quickly is seeking contactwith the other floor panel 1 before it can pivot outward too far.

In the embodiment of FIG. 17, also no distal stop-forming portion ispresent, as a result of which the locking element can be pressed intothe recess 13 more smoothly. As can be seen in FIG. 18, the lock-up body14, instead of a purely pivoting movement, then possibly also mayperform a rolling movement, whereby it possibly distances itselfsomewhat from the proximal lateral wall 25, however, due to settling ofthe whole when the floor is walked upon, or under the influence of otherforces, indeed can take place against this wall again.

In the embodiment of FIG. 17, the locking element also is provided withan attachment portion 50 especially provided for this purpose, whichportion in this case is performed as a clamped part. As clearlyrepresented in FIG. 19, the clamping action herein is obtained by anelastic bending and/or deformation of the attachment portion 50.

FIG. 17 also shows that the female part 9 can be performed with arelatively low hook-shaped part 10 and further may have such a shapethat two of such floor panels 1 can be brought into each other at therespective edges also by sliding them towards each other, whether or notassisted by the fact that the hook-shaped part 11 possibly iselastically bendable. This manner of joining is illustrated in FIG. 20.Herein, two possibilities can occur. When the floor panels 1 are held inthe same plane and are moved towards each other in this manner, such asindicated by arrow S1, the hook-shaped part 11 is forced to bend outelastically downward. When the floor panels 1 have been slid with theirupper edges against each other, the lock-up body 14 automatically comesinto the locking position, whereas the bent-out hook-shaped part 11 alsobounces back and comes to sit behind the male part 8. When the floorpanel 1 comprising the lock-up body 14 at its edge to be coupled isfreely movable in height, then during joining a movement according toarrow S2 will take place, wherein the male part 8 arcuately slides overthe hook-shaped part 11 in order to finally drop until a locking isobtained. Of course, also combinations of both movements may take place.

As schematically indicated in FIG. 17 by arrow S3, the representedcoupling parts also allow that two of such panels can be coupled and/oruncoupled by an angling movement, such by applying a suitable height ofthe hook-shaped part 11 and/or a suitable inclination of the contactsurfaces 51-52.

It is clear that all characteristics described above by means of FIGS.17 to 20 optionally can also be integrated into other embodiments of theinvention.

It is noted that the locking element 12 according to the invention canbe taken up into the sides 2-3 to be coupled at various locations. Forexample, FIGS. 21 to 23 represent three embodiments, wherein thiselement is provided at the female part 9 instead of the male part 8,whereas FIG. 24 represents an embodiment, wherein the locking element 12is provided in the edge region and thus not in the actual seat where themale part fits into the female part.

The embodiment of FIG. 22 shows that the press-on portion 15 also mayhave a bent or folded-over shape.

FIG. 23 represents that the locking element can also be attached in therecess 13 by means of glue 53, possibly by means of a portion especiallyprovided for this purpose, such as an attachment lip 54, which, forexample, is in connection with the press-on portion 15.

It is noted that the locking element 12, or, thus, the strip, as suchcan be provided with one or more elastic bending zones, which eitherform a connection between the actual press-on portion 15 and the lock-upbody 14, or a connection between several portions of the press-onportion 15, or still between other portions. Such bending zones allowobtaining the desired mutual movability among the composing parts. Theembodiment of FIG. 23 is an example thereof, wherein two flexiblebending zones 15A are provided, between the attachment lip 54 and thepress-on part 15 on the one hand and the press-on part 15 and thelock-up body 14 on the other hand.

Preferably, such bending zones 15A are formed by coextrusion during themanufacture of the locking element 12.

In general, it is preferred that a locking element according to theinvention provides for a stable support in vertical direction, whereasin horizontal direction, thus, in the pivoting direction, a flexiblemovability is effected. The application of co-extruded parts assiststherein.

In the case of rectangular floor panels, either oblong or square, it isclear that coupling parts can also be provided at the second pair ofopposite sides, which coupling parts, in coupled condition, preferablyalso offer a horizontal as well as a vertical locking. These couplingparts at the second pair of sides also can be performed as a “push-lock”coupling, whether or not in accordance with the present invention.Preferably, however, at the second pair of sides coupling means will beapplied allowing a mutual coupling by means of a pivoting movementbetween two floor panels to be coupled and/or by means of a shiftingmovement resulting in a snap-on connection. Such coupling parts arewidely known from the state of the art and are described, for example,in WO 97/47834.

In the most preferred embodiment, at the second pair of sides 55-56coupling parts 57-58 will be applied allowing at least a connection bymeans of a pivoting movement, as this allows installing the floorpanels, as illustrated in FIGS. 25 and 26, in a simple manner. A newfloor panel 1C to be installed then can be simply angled at its side 55into the preceding row of floor panels 1A, and such just next to apreceding floor panel 1B in the same row. When being angled down, themale part of the new floor panel 1C to be installed then automaticallyengages in the female part of the preceding floor panel 1B, without thenecessity of performing another operation. In the case of oblong floorpanels 1, thus, it is preferred that the so-called “push-lock”connection then is situated at the short sides.

FIG. 27 represents an example of the seventh aspect of the invention.According to this aspect, the locking element 12 consists of a syntheticmaterial strip provided in a recess 13, which strip, in the coupledcondition of two floor panels 1, comes into contact with both floorpanels 1 and thereby forms a seal, wherein between the upper side 59 ofthe floor panel 1 and the synthetic material strip also a seal 60-61 ispresent at the panel edges 62-63. The intention herein is that thesynthetic material strip is applied as a seal against the infiltrationof water and thereby offers at least a barrier which at leastdecelerates and preferably completely blocks the possible infiltrationof water in between the coupling parts 4-5, whereas the seal 60, 61,respectively, at the panel edges is intended for protecting the panelmaterial 64, which mostly is based on wood, as such against thepenetration of water. Possible water which might infiltrate in betweentwo floor panels 1 then can not or only with difficulty infiltrate up tobeneath the floor panels 1, whereby the risk of rotting and mouldformation beneath the floor panels 1 is restricted, whereas this wateralso can not penetrate into the floor panels 1 themselves and thus adamage at the floor panels 1 themselves, for example, by swelling, isexcluded. The moisture present above the synthetic material strip canevaporate in due course.

In the represented example, the seal against moisture penetration isformed at one side 3 by the contact 65 and at the other side 2 by one ormore of the contacts 66, 67 or 68. In order to guarantee a bettersealing, the locking element can be provided with one or more sealingmaterial portions 69, for example, of a relatively soft syntheticmaterial or rubber, which are present at the location of the contacts65-66-67-68 at the locking element 12. These sealing material portionscan be provided at the synthetic material strip in any manner. In apractical embodiment, this will be performed by means of coextrusion.

The seals 60-61 at the panel edges 62-63 may have any form. Asrepresented, they are formed, for example, by an impregnation layer or acovering layer, such as a lacquer or varnish layer. They extend from atthe top layer downward, each time at least up to one of the locationswhere said contacts are realized. According to a not representedvariant, such seal also may consist in that the top layer extends up toa location where one of the contacts is realized, for example, byapplying a top layer which extends over the upper edges downward.

According to the seventh aspect, it is intended that the top layer alsois waterproof. Moreover, it then may consist of any material, such as alaminate, a film, a lacquer layer, a water-repellent or waterproofprint, a varnish or the like.

It is clear that in this manner both the infiltration of water as wellas the penetration of water into the panel edges is avoided.

It is noted that floor panels which are installed in rows, and then inparticular oblong floor panels, show the feature that the floor panelswill align in the longitudinal direction of the rows and mostly willadjoin well with their sides against each other, whereas at the sidesdirected perpendicularly to the rows then openings will occur moreeasily, due to the fact that such floor panels, as a result ofproduction tolerances, often do not have perfectly perpendicularlyaligned sides. At the location of such openings, a fast infiltration ispossible, and a sealing by means of somewhat elastic coatings on theupper edges of the floor panels mostly is not effective, as the openingsare too large to be bridged thereby. Thus, in particular at the locationof these sides a sealing principle according to the seventh aspect ofthe invention will show its benefits. In view of the fact that the sides55-56 of the floor panels, which are intended to extend in thelongitudinal direction of the rows, due to the automatic alignment,adjoin to each other rather well, the problem of infiltration at thesesides is little or not at all present and, if one wishes to provide asealing at all four sides, it may suffice that at these sidesexclusively a coating or impregnation is provided on the panel edges, asindicated by reference numbers 71-72 in FIG. 26.

When, as in FIG. 27, use is made of a press-on portion 15 which isclamped, and which is formed by co-extrusion, then it is preferred thatthe transition T is situated closer to the lock-up body 15 than in theembodiment of FIG. 6. With suitable dimensions in free condition, it maythen be obtained that in the mounted condition a force is generatedholding the locking element 12 in permanent contact with the supportsurface 21.

FIG. 28 represents a variant, which makes clear that the inventive ideaof the use of a co-extruded locking element 12 in a so-called“push-lock” system is not restricted to embodiments with a pivotablelock-up body. According to FIG. 28, the lock-up body 14 is displaceableand consists of a relatively hard synthetic material, whereas thepress-on portion 15 consists of flexible and elastic synthetic material.Herein, the co-extruded press-on portion 15 functions as an elastic masssituated behind the lock-up body 14 in a spring-like fashion.

FIG. 29 represents another variant, which is comparable to that of FIG.17. Herein, the difference consists in that the hook-shaped part 11 ofFIG. 29 is realized considerably higher than in the embodiment of FIG.17, such that the contact surfaces 51-52 at least partially are situatedhigher than the support surface 21 of the lock-up body.

FIG. 30 represents a preferred variant of an embodiment according to theinvention, wherein the locking element 12 is provided in the proximalside of the female part. In respect to the embodiment of FIG. 29, thisoffers an important advantage. In FIG. 29, the edge 73 is maderelatively sharp and straight in order to obtain that the lock-up body14 in free condition still is seated beneath the edge 73. When, duringlowering of a floor panel 1 in a manner as depicted in FIG. 25, thesides 2-3 to be coupled to each other do not perfectly correspond, forexample, because the floor panels 1B-1C, seen in top view, areoverlapping somewhat, for example, as a result of the warping of floorpanels in the preceding row, or as a result of un-squareness of thepanels, a condition is created as depicted in FIG. 31, wherein then theedge 73 scrapes along the upper edge 74. In the embodiment of FIG. 30,this can easily be counteracted in that the edge 73 can be performedwith an adequate chamfer, as a consequence of which a possible contactbetween edge 73 and upper edge 74 rather results in a sliding movementalong each other than in a scraping effect.

Also, in an embodiment according to FIG. 29, the locking element 12,when the right-hand floor panel is moved downward, comes into contactwith the sharp upper edge 74 of the left-hand floor panel, whereby alsoa scraping effect may be created, which can impede the installation. Incontrast, the embodiment of FIG. 30 does not show this disadvantage, inview of the fact that the rounded underside of the male part then willslide smoothly along the locking element.

FIG. 30 also relates to an embodiment meeting the eighth aspect of theinvention mentioned in the introduction, more specifically in that theedges of the floor panels 1 can be joined into each other by a shiftingmovement S1.

Moreover, the embodiment of FIG. 30 shows the following characteristics:

-   -   the coupling parts 4-5 concerned are realized such at the        aforementioned sides, that they allow a locking and/or unlocking        of two of such floor panels in mutual respect by mutually        angling them into each other, out of each other, respectively;    -   in free condition, the lip-shaped lock-up body 14 protrudes        outward in an inclined manner;    -   the lock-up body 14 is provided in the proximal side of the        female part 9;    -   the female part 9 and the male part 8 comprise contact surfaces        52-51 at their distal extremities, said surfaces being performed        upwardly inclined in distal direction;    -   the lip-shaped lock-up body 14 is a pivotable body.

In FIG. 30, it is also represented that the lock-up body 14, and stillbetter the entire locking element 12 realized as an insert, is maderelatively local, by which in particular is meant that it is onlypresent between a first and a second horizontal level, the firsthorizontal level N1 of which is situated at a distance beneath the upperside of the coupled floor panels, whereas the second horizontal level N2is situated lower than the first, however, higher than the lowermostpoint of the male part. Further, FIG. 3 also shows that said lock-upbody 14 extends over a height H which is at least 40% and still betterat least 50% of the height difference between the upper side of suchcoupled floor panels and the lowermost point of the male part, i.e., D7.It is clear that these characteristics are not limited to the embodimentof FIG. 30.

In the case of a pivotable embodiment, wherein one floor panel can beangled into the other or out of it, it is preferred that, as indicatedin FIG. 30, the horizontal distance D6, as measured from the upper edgesof the floor panels up to the cooperating point of the contact surfaces51-52, which is situated farthest away from these upper edges, is atleast 1.3 times the distance D7 between the upper side of the floorpanels and the underside of the male part, which allows a smooth anglingmovement.

In order to allow a smooth angling in and out and/or shifting together,the highest point 75 preferably is situated at a level N3, which islower than the lowermost point of the lock-up body 14.

FIG. 30 represents a particular construction of a press-on portion 15,wherein it is clear that this construction also can be applied in otherembodiments of floor panels according to the invention. This press-onportion, more particularly the construction thereof, shows the followingcharacteristics:

-   -   that the press-on portion 15, viewed in cross-section, is        realized as a pivot arm, which is supported or held next to one        extremity and adjoins at the other extremity, by means of a        hinge and/or bending zone 76, to the rear side of the lock-up        body 14;    -   that said pivot arm has a hinge and/or bending zone 76-77,        respectively, at both extremities, in this case formed by        thinner parts in the material; moreover, the zone 77 preferably        is situated such in respect to an underlying support surface        that an upward-directed pivoting movement is possible in a        smoother manner than a downward-directed one;    -   that the press-on portion 15 is realized as a mechanism which,        when the lock-up body is compressed, will provide for that this        lock-up body becomes positioned with one extremity against a        support surface 21; more particularly, a compression K1 results        in a pivoting movement K2, as a result of which the lock-up        element 14 is pressed upwards according to arrow K3 against the        support surface 21;    -   that the above-mentioned mechanism consists of a pivot arm        connecting, one the one hand, to the rear side of the lock-up        body and, on the other hand, is supported by means of a support        portion, such as a support collar 78.

Finally, it is noted that the floor panels according to the invention ingeneral can be realized such that in coupled condition a so-called“pre-tension” is created, which means that the floor panels at theircoupled sides are pressed towards each other by means of a tensionforce. Herein, the tension force can be supplied in any manner. Forexample, it may be generated by the elastic bending of the lip borderingthe underside of the female part. Herein, the principle can be appliedwhich is known from WO 97/47834, more particularly from FIG. 23 of saidWO 97/47834.

It is also clear that floor panels of the present invention can also beequipped with an anti-creak system, more particularly by application ofthe principle described in WO 2006/032398.

FIG. 32 shows another embodiment meeting the various aspects and inparticular the ninth aspect of the invention. Herein, the lock-up body14 and the attachment portion 50 consist of a relatively rigid materialand are connected to each other by coextrusion by means of a materialpart 79 made as a hinge part, which material part consists of a moreflexible and elastic material.

The lock-up body 14 globally forms an angle with the attachment portion50 and reaches with the extremity functioning as a support portion 20 upto beyond the actual attachment portion 50, in such a manner that at thelocation 80, where the lock-up body 14 passes along the attachmentportion 50, the distance between the lock-up body 14 and the attachmentportion 50 is smaller than the distance from the—in this case upwardlyprotruding—extremity of the lock-up body 14 to the attachment portion50.

The material part 79 is situated between the actual attachment portion50 and said protruding beyond it extremity of the lock-up body 14. Thisdesign has the advantage that the lock-up body 14, due to the smallmaterial quantity at the location 80, can hardly be displaced in respectto the attachment portion 50, with the exception of an angling movement,whereas in upward direction sufficient flexible material of the materialpart 79 is present in order to hold the lock-up body 14 in a certainposition and to allow the desired elastic movement thereof. Stillanother advantage is that, when the lock-up body 14 is angled in, thematerial on the location 80 is compressed and the lock-up body 14 alsois pushed upward, as a consequence of which it remains in contact withthe support surface 21.

In mounted condition, the locking element 12 preferably is supported atleast on three locations, on the one hand, at the bottom at the heightof the support collar 78, at the top by the upper side 81 of thematerial part 79, as well as at the height of the represented ribs 82.

FIG. 32 also shows that the attachment portion 50 is providedsubstantially flat in the recess 13, in other words, that the direction83 in which this attachment portion 50 extends, deviates little or notat all from the plane of the floor panels. By altering this direction83, which a manufacturer of floor panels can do in a simple manner bypositioning the recess 13 somewhat differently, different functioningcharacteristics in respect to angling the lock-up body in and out can beobtained, such that an optimization is possible.

FIGS. 33 to 37 represent another variant of the invention. A number ofdifferences in respect to the embodiment of FIG. 32 will be discussed inthe following.

A first difference consists in that the locking element 12 in verticaldirection is supported in the recess 13 by means of only three supportportions, or at least substantially by only three support portions, onesupport portion of which is formed by the aforementioned support portion20 of the lock-up body 14. The other two support portions, 84 and 85,respectively, preferably are situated at the upper side and underside ofthe actual attachment portion 50. More particularly, it is preferredthat the support portion 84 situated at the top is located in respect tothe floor panel more proximally than the support portion 85 situated atthe bottom. Still more particularly, it is preferred that the supportportion 84 of the upper side is located at the—situated proximally inrespect to the floor panel 1—extremity of the actual attachment portion50, whereas the support portion 85 is located at the distally situatedextremity. A considerable difference from the embodiment of FIG. 32 thusis that the material part 79, at least in the free condition, does notform a support point. It is clear that one and the same support portionas such may comprise several contact points, for example, if it shouldhave a ribbed surface.

In this embodiment, the locking element 12 is configured such that inthe mounted, however, not impressed condition, namely the one from FIG.33, a certain clamping thereof in the recess 13 is created. This isobtained, for example, by the elastic deformation of the actual body ofthe attachment portion 50 from the position represented in dashed linein FIG. 33 to the position represented in solid line, which deformationis achieved during clamping of the locking element 12 in the recess 13.

A second difference consists in that the actual attachment portion 50 isconfigured and attached in the recess 13 such, that during joining oftwo floor panels 1 a certain movability of the actual attachment portion50 is possible. In the represented example, the support portion 85 tothis aim is provided with a guiding surface 86, which can cooperate withan inclined guiding surface 87 at the floor panel, whereby a smalldisplacement 88 of the attachment portion 50 is possible, such as willbe described in the following by means of FIGS. 34 to 37.

FIGS. 34 to 37 represent successive conditions of the locking element 12during joining of two floor panels 1. FIG. 34 shows the rest position.Due to the tension force in this entity, the support portion 85 has thetendency to slide downward along the guiding surface 8 until it reachesthe represented position. FIGS. 35 and 36 represent successiveconditions, wherein the right-hand panel is angled down and the lock-upbody 14 is pushed aside. Due to the fact that on the location 80 verylittle material of the material portion 79 is present between thelock-up body 14 and the actual attachment portion 50, this latter,starting from a certain moment, is also forced somewhat inward, whereinit moves with its guiding surface 86 along the guiding surface 87, untilit reaches a condition, as depicted in FIG. 36. Herein, the attachmentportion 50, so to speak, makes room for the movement of the lock-up body14 and thereby performs a more or less rotating displacement 88, such,for example, until it comes with its extremity 89 into contact with thedeepest point of the recess 13. Hereby is obtained, amongst others, thatthe support portion 20 rotates practically exclusively at its placealong its highest point and performs little or no rolling movement alongthe floor panel. Further, the whole may be designed such that the actualattachment portion 50, after the locking of the floor panels, also moreor less arrives back at its initial location, as depicted in FIG. 37.The downward-protruding support portion 85 thus indeed provides for ablocking function, which determines the normal position of the lockingelement 12 in the recess, however, with a certain load in fact willallow an extra movement 88.

As represented in FIG. 36, the locking element 12 according to theinvention may also be configured such that in the most impressedcondition, a free space 90 is created between the support portion 20 andthe wall of the recess 13. The proper configuration for this purpose canbe determined by tests. An advantage thereof is that during the initialbackward movement of the lock-up body 14, there is no friction presentbetween the support portion 20 and the wall of the recess 13, whichmight prevent the smooth pivoting outward of the lock-up body 14.

As is represented in FIG. 34 by dashed line 91, according to a variant adeformation may be provided in the wall of the recess 13, whichdeformation cooperates with a deformation in the attachment portion 50,as a result of which the locking element 12, so to speak, can be fixedlyattached in the recess 13 by means of a snap-on connection.

It is clear that the essential characteristics of the embodiments of theFIGS. 32 and 33-37 consist in that the locking element 12, viewed incross-section, consists at least of an actual attachment portion 50, alock-up body 14, which can perform at least an angling movement, and amaterial part 79, which is present between the attachment portion 50 andthe lock-up body 14, which material part consists of a material which ismore flexible and elastic than the material of the lock-up body 14 andwhich thereby functions at least as a hinge part. From the above, it isclear that all other characteristics described by means of FIGS. 33 to37 are facultative and that all these facultative characteristics can bemutually combined at random. Herein, the most important preferredcharacteristic consists in that the attachment portion 50, the materialpart 79 and the lock-up body 40 by means of coextrusion are realized asa one-piece strip. Herein, it is preferred that the actual attachmentportion 50 and the lock-up body 14 are manufactured of one and the samematerial, whereas the material part 79 consists of a more flexiblematerial. In principle, the same basic substances can be applied forboth materials, however, they may differ from each other by the additionof additives, such as plasticizers. The material of the material part 79preferably behaves like a relatively soft rubber, whereas the materialof the actual attachment portion 50 and of the lock-up body 40preferably behaves like a classic synthetic material, such as commonPVC, and thus, in view of the small dimensions in cross-sections, alsobehaves in a relatively rigid manner.

It is clear that the embodiment according to FIGS. 33 to 37 also allowsthat two of such floor panels can be brought into each other at therepresented edges not only by means of a downward movement, but also bymeans of an angling movement or by shifting towards each other.Unlocking may take place, for example, by angling the floor panels outof each other. Also, it is not excluded to provide a recess in thisembodiment, analogous to the recess 46 in FIGS. 15 and 16, such thatunlocking by means of a rod 47 is possible.

In general, it is noted that by the characteristic that “the supportportion, for example, 20, is rotatable against a support surface, forexample, 21”, it is intended that there is a contact at least duringpart of the rotation and that it thus is not excluded that there is nocontact for a part of the rotation, as becomes clear from the example ofFIG. 36, wherein in a certain position indeed a free space 90 ispresent. The contact will normally be present indeed from a certainangling-out of the lock-up body.

The fact that such support portion 20 is rotatable against a supportsurface 21, must be interpreted in the broadest sense. The rotation canprovide for a local rotation of the support portion 20, as well as arolling movement along the support surface, as well as a combination ofboth. Also, it is not excluded that the turning movement is combinedwith shifting. A local rotation, or “pivoting against a support orrotation point”, may concern a turning around a point or zone which is,are, respectively, situated in the support surface 21, as well as arotation point or rotation zone at a distance from the support surface.

In the production of floor panels according to the invention, the recess13 can be realized in any manner. According to a preferredcharacteristic, this takes place by means of a milling treatment, whichis performed when realizing said female coupling part.

The application of the strip-shaped locking element 12 in the recess 13may also be performed in any manner. In the following, twonon-restrictive embodiments of methods for this purpose are described,which can be applied within the scope of the present invention.

According to a first technique, the strip-shaped locking element 12systematically is fixedly pressed on in the recess 13, preferably isrolled into it. Preferably, this takes place, as represented in FIG. 38,by displacing the floor panels 1, which mostly are lying upside down, bymeans of a conveyor 92, supplying thereto a strip 93 from which thestrip-shaped locking elements 12 have to be cut off, and fixedlypressing on this strip 93, the locking elements 12 cut off therefrom,respectively, in the recesses 13 of the successive floor panels 1 bymeans of a locally installed rotating press-on roll 94. FIGS. 39 to 41show, how the strip is pressed on in the recess 13 by means of thepress-on roll 94, which to this aim can be provided with a profiledsurface 95.

It is clear that the strip 93 can be supplied from a stock, for example,a wound stock. Further, a cutting device 96 is present for separatingthe locking elements 12 at a suitable length from the strip 93, whichdevice is illustrated schematically only. It is clear that in practicethe necessary guiding elements will be present in order to have thestrip 93 and the locking element 12 follow the correct course, of whichthe guiding element 97 in FIGS. 40 and 41 is an example.

FIG. 42 shows a variant, wherein according to the invention a method isapplied wherein a cut to length strip-shaped locking element 12 over itsentire length simultaneously is pressed into the recess 13. Asrepresented in FIG. 42, this preferably is performed by means of adevice with a slider or plunger 98, with which the locking element 12laterally is pushed over its entire length at one go into the recess 13.As represented, the device preferably comprises a holder 99, in which aspace 100 is defined, in which a locking element 12 to be applied can betaken up and wherein the plunger 98 can be shifted. Then, the holder 99,together with the plunger 98 present therein and the locking element 12present therein, is positioned opposite to the edge of a floor panelconcerned, as illustrated in FIG. 42, after which, by displacing theplunger 98 to and fro to the right, the locking element 12 is broughtfrom the position represented in solid line to this position representedin dashed line, after which it remains in the recess 13.

FIG. 43 schematically shows how the device from FIG. 42 can be appliedin practice. In this example, the floor panels 1 are displaced along aconveyor 92. The holder 99, too, can perform various displacements, aswill become clear from the function sequence described in the following.

Initially, the holder 99 is situated in a position 101. First, a strip93 is supplied to the holder, which strip is provided in the space 100.As represented, this may be realized, for example, by displacing theholder 99 along a press-on roll 103 with which the strip 93, which issupplied from a not represented stock, is directed into the space 100 ofthe holder 99, as illustrated for the position 102 of the holder 99. Thelength necessary for forming the locking element 12 is then cut off bymeans of the schematically represented cutting device 104. In themeantime, a floor panel has arrived in a position 105. Subsequently, theholder 99 can follow the movement of a passing floor panel 1, as aresult of which they come into positions 106 and 107, respectively.During this movement, the holder 99 and the floor panel concerned can bepresented to each other, for example, by laterally displacing the holder99 until it reaches position 108. Hereby then the condition of FIG. 42is obtained, after which it suffices to activate the plunger 98 in orderto bring the locking element 12 into the recess 13. As described above,all this can take place during the continuous conveyance of the floorpanels, for example, after they exit the milling device and before theyare packaged. The holder 99, or possibly several applied holders 99,then can be displaced to and fro through all abovementioned positions.Also, multiple holders on a conveyor belt might be used, wherein aholder then is brought from position 108 back to position 101, whilealready one or more other holders pass through the same trajectory.According to a variant, panels also may be supplied stepwise instead ofcontinuously to an insertion device for locking elements 12.

It is clear that by a lock-up body 14 which can be pivoted or bent out,it is intended that it can be pivoted or can be bent out in the plane ofa cross-section.

Generally, it is noted that the support portion of the lock-up body,around which it is rotatable, is a support portion which is intended totake up the forces when the floor panels attempt to get away from eachother in upward direction. From US2007/0006543, which corresponds toWO2007/008139, also a rotatable locking element is known, which,however, contrary to the invention, does not rotate around a supportpoint which, as above, is intended to provide for a lock-up supportfunction which counteracts the unlocking of the floor panels.

By a “rigid” lock-up body, it is meant that this rigidity exists atleast in a plane according to the cross-section.

The present invention is in no way limited to the embodiments describedby way of example and represented in the figures, on the contrary maysuch floor panels be realized in various forms and dimensions, withoutleaving the scope of the invention.

From the above, it is clear that the invention, and in particular thelocking element according to the invention, can be employed in variousfloor panels, amongst others, in laminate floor panels, prefabricatedfloor panels, such as so-called “engineered wood”, solid parquet, veneerparquet, as well as floor panels which are provided with any top layer,for example, vinyl, linoleum, stone, metal and the like.

It is noted that the core of such floor panel not necessary has toconsist of wood or a product on the basis of wood and in principle mayconsist of any material, thus, for example, also synthetic material.

1. A floor panel, wherein the floor panel comprises, at least at twoopposite sides, coupling parts with which two of such floor panels canbe coupled to each other; wherein the coupling parts form a horizontallyactive locking system and a vertically active locking system; whereinthe horizontally active locking system has a male part and a femalepart, which allow to connect two of such floor panels to each other byproviding one of these floor panels with the pertaining male part, bymeans of a downward movement, in the female part of the other floorpanel, the male and the female part being substantially made from theactual panel material; wherein the vertically active locking systemcomprises a locking element, which is provided in the form of an insertin one of the sides; wherein the locking element comprises a lock-upbody, said lock-up body forming a stop-forming locking portion which cancooperate with a locking portion of a similar coupled floor panel; andwherein, in a coupled condition of two of such floor panels, the floorpanels at their coupled sides are pressed towards each other by means ofa tension force.
 2. The floor panel of claim 1, wherein the tensionforce is generated by elastic bending of a lip bordering the undersideof the female part.
 3. The floor panel of claim 1, wherein the lockingelement substantially serves as a locking element taking part in thevertical locking.
 4. The floor panel of claim 3, wherein the lockingelement exclusively serves as a locking element taking part in thevertical locking.
 5. The floor panel of claim 1, wherein the horizontallocking exclusively is performed by the male and the female part.
 6. Thefloor panel of claim 1, wherein the stop-forming locking portion issituated at an extremity of the lock-up body.
 7. The floor panel ofclaim 1, wherein the lock-up body is lip-shaped.
 8. The floor panel ofclaim 1, wherein the lock-up body is pivotable.
 9. The floor panel ofclaim 1, wherein the male part is formed by a downward-directedextremity of a hook-shaped part and the female part consists of a seatformed by means of an upward-directed hook-shaped part.
 10. The floorpanel of claim 1, wherein the insert consists of a strip of syntheticmaterial.
 11. The floor panel of claim 1, wherein the locking elementconsists of a strip which is attached in a recess in the floor panel andthat thereby attachment provisions are present, which retain the stripin the recess.
 12. The floor panel of claim 1, wherein the lockingelement is situated in a distal side of the male part.
 13. The floorpanel of claim 1, wherein the locking element is situated in a proximalside of the female part.
 14. The floor panel of claim 1, wherein thefloor panel is rectangular, either oblong or square; wherein couplingparts are also provided at a second pair of opposite sides, which, incoupled condition, also offer a horizontal as well as a verticallocking; wherein at the second pair of opposite sides the coupling partsallow a mutual coupling by means of a pivoting movement, such that thefloor panel can be angled in at one of its sides of the second pair intoa preceding row of floor panels and such just next to a preceding floorpanel in the same row and, when being angled down, the male part of thefloor panel then automatically engages in the female part of thepreceding floor panel.
 15. The floor panel of claim 14, wherein thefloor panel is rectangular and oblong; and wherein the second pair ofopposite side forms the pair of long sides.